Since loosening the radiator drain is dangerous while the coolant is pressurized, check that it isn't loose when you service your thermostat. Pour the coolant into a clean vessel if it's still clean and make sure the new thermostat works for the vehicle and its engine. The thermostat housings on 3.9L, 5.2L and 5.9L engines are held in place with a gasket that helps stop them from sticking as they are removed. First, break the negative battery connection and let all the fluid drain from the cooling system, lowering the coolant to below the thermostat. Air-conditioned vehicles need the support bracket near the rear of the generator taken off, with note that the generator must be partially removed during this process. Remove next the accessory
Drive Belt and the nuts that hold the generator to the chassis, but don't disconnect the wiring. If your vehicle has a 4Wd system, unplug the wiring for the 4Wd indicator lamp. Reach the thermostat gasket by getting the generator out of the way. When using constant tension hose clamps, pick up special Clamp tool number 6094 or Hpc20 from Snap-On for larger sizes and always be sure to wear safety glasses. Original equipment clamps with the same letters or numbers should be the only ones you replace constant tension clamps with. Open the upper hose clamp and remove the hose from the thermostat housing and reposition the wiring harness behind the housing so you have access while working. After that, unscrew the bolts behind the housing and take out the housing, gasket and thermostat, putting the old gasket aside. First, clean any dirt from the spots where the
Intake Manifold and thermostat housing mate, then put the thermostat (upper side down) into its groove, cover it with the gasket and put it into the thermostat housing. Make sure the word Front is visible on the thermostat housing when it's facing the vehicle's front and then secure the housing to the intake manifold with the two bolts, tightening them to 23 Nm (200 inch lbs.) torque. Attach the radiator upper hose to the thermostat housing, taking care that the serpentine accessory drive belt is properly positioned to keep the engine from overheating because of wrong
Water Pump rotation. For vehicles that are air-conditioned, set up the generator, then bolt it in at 41 Nm (30 ft. lbs.) torque. After that, set up the support bracket, tighten its bolts to 64 Nm (30 ft. lbs.) torque. Install the belt again, insert the radiator fluid, reattach the negative
Battery Cable and start the engine, looking for any leaks as the engine is warming up.